Aluminum alloy vehicle structural component defining an out-of-plane aperture

ABSTRACT

An aluminum alloy vehicle structural component defining an out-of-plane aperture with its main portion. A recessed portion is inset from the main portion having a bed sub-portion out-of-plane with the main portion that defines the aperture. The recessed portion also provides a strain hardened sub-portion, or stiffened ring of material, around the aperture. When the main portion is subjected to in-plane tension due to bending, the strain primarily concentrates along the strain hardened sub-portion (the stiffened ring) and by-passes the aperture. As a result the perimeter of the aperture undergoes less straining than if the aperture was in-plane with the main portion. The out-of-plane aperture, the bed sub-portion surrounding the aperture, and the strain hardened sub-portion surrounding the bed sub-portion may improve the overall structural robustness of the aluminum alloy structural component when subjected to in-plane tension.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a division of U.S. application Ser. No. 14/297,762filed Jun. 6, 2014, now U.S. Pat. No. 9,296,432 issued on Mar. 29, 2016,the disclosure of which is hereby incorporated in its entirety byreference herein.

TECHNICAL FIELD

This disclosure relates to pickup trucks having aluminum-alloy vehiclestructural components, and more specifically to the forming of anaperture out-of-plane from a main portion of the structural components.

BACKGROUND

Pickup trucks are motor vehicles with a front passenger area, oftenreferred to as a cab, and an open top rear cargo area, often referred toas a box. The box usually has a substantially flat bed from which twosidewalls and a forward interconnecting headboard extend upwardlytherefrom. Pickup trucks may also employ a bottom hinged door, commonlyreferred to as a tailgate, hinged at the rear edge of the bed andclosable to provide a fourth wall for the cargo area. Cabs and boxes maybe separate assemblies or part of the same unibody structure. Pickuptrucks are popular largely because the box allows them to be utilized inso many different ways, including carrying a variety of types of cargoand towing various types of trailers.

Traditionally the majority of body structures on pickup trucks have beenformed from steel alloys. Through years of experience, pickup truckdesigners have learned how to engineer steel truck body parts thatwithstand the variety of demanding pickup truck applications. Thecurrent regulatory and economic environments have increased theimportance of making pickup trucks more fuel efficient as well asfunctional and durable. One way to reduce the fuel consumption of avehicle is to reduce vehicle structure weight.

Aluminum alloys typically have a higher strength to weight ratio thansteel alloys. Consequently, replacing steel with aluminum offers thepotential for weight reduction. However, the elastic modulus of aluminumis generally lower than the elastic modulus of steel. As well,fabrication techniques and methods of joining parts that work well forsteel parts may not work well for the same aluminum part. Due to theseand other differences, simple material substitution does not necessarilyproduce an acceptable design.

Aluminum alloys are generally identified by a four-digit number, thefirst digit of which typically identifies the major alloying element(s).For example, the major alloying elements in 6xxx or 6000 seriesaluminium alloy are magnesium and silicon, while the major alloyingelement of 5xxx or 5000 series is magnesium and for 7xxx or 7000 seriesis zinc. When describing a series of aluminum alloys based on the majoralloying element, the first number may be followed by three x′s (upperor lower case) or three 0's (zeros). Additional numbers represented bythe letter ‘x’ or number ‘0’ in the series designation define the exactaluminum alloy. For example, a 6061 aluminum alloy has a composition of0.8-1.2% Magnesium, 0.4-0.8% Silicon, 0.15-0.4% Copper, 0.04-0.35%Chromium, 0-0.7% Iron, 0-0.25% Zinc, 0-0.15% Manganese, and 0-0.15%Titanium. Different alloys provide different trade-offs of strength,hardness, workability, and other properties.

In addition, five basic temper designations may be used for aluminumalloys which are: F—as fabricated, O—annealed, H—strain hardened,T—thermally treated, and W—as quenched (between solution heat treatmentand artificial or natural aging). The temper designation may be followedby a single or double digit number for further delineation. For example,aluminum with a T6 temper designation has been solution heat treated andartificially aged, but not cold worked after the solution heat treatment(or such that cold working would not be recognizable in the materialproperties).

SUMMARY

One aspect of this disclosure is directed to an automotive componentdefining an out-of-plane aperture. The component is an aluminum alloystructural component having a main portion surrounding a recessedportion. The recessed portion has a strain hardened sub-portionconnecting a bed sub-portion to the main portion. The bed sub-portion isout-of-plane with the main portion and defines an aperture. Thestructural component may be a 6000 series aluminum alloy. The structuralcomponent may be 6111 aluminum alloy.

In this aspect, the bed sub-portion may be substantially parallel withthe main portion. The bed sub-portion may also have a width of at least6 millimeters extending substantially perpendicularly from any point ona perimeter of the aperture. The main portion may have a first thicknessand the bed sub-portion may have a second thickness substantially equalto the first thickness. The first and second thicknesses may be at least2 millimeters.

The main portion may have a substantially flat first surface. The bedsub-portion may have a substantially flat second surface. The secondsurface may be substantially parallel with the first surface. A depthbetween the first surface and the second surface may be at least 2.5times the first thickness. The depth may be at least 5 millimeters.

A first interface may extend between the main portion and the strainhardened sub-portion having a first radius. A second interface mayextend between the strain hardened sub-portion and the bed sub-portionhaving a second radius. The first and second radii may curve in oppositedirections. The first and second radii may be at least 3 times the firstthickness. The first and second radii may be at least 6 millimeters.

The aperture may be substantially circular, however other shapes may beused and multiple apertures may be clustered together. The aperture mayhave a diameter of at least 16 millimeters. The aperture may be anaccess hole used during assembly of the component. The recessed portionmay extend inwardly into the structural component from an outer surfaceor may extend outwardly from the structural component from an innersurface.

Another aspect of this disclosure is directed to a pickup truck with a6000 series aluminum alloy structural component. The 6000 seriesaluminum alloy structural component has a main portion surrounding a bedsub-portion out-of-plane with the main portion. The 6000 series aluminumalloy structural component also has a strain hardened sub-portiondisposed between the main portion and the bed sub-portion. The bedsub-portion defines an aperture, thus providing for the aperture beingout-of-plane with the main portion. The structural component may be partof a roof-header assembly.

The bed sub-portion extends substantially parallel with the main portionfrom a perimeter of its defined aperture by a minimum of 6 millimeters.The structural component may have a substantially constant thickness.The thickness may be at least 2 millimeters. The bed sub-portion mayhave a depth from the main portion of at least 2.5 times the thickness.The depth may be 5 millimeters.

A first interface between the main portion and the strain hardenedsub-portion may have a first radius of at least 3 times the thickness.The first radius may be at least 6 millimeters. A second interfacebetween the strain hardened sub-portion and the bed sub-portion may havea second radius of at least 3 times the thickness. The second radius mayhave a dimension substantially the same as the first radius. The secondradius may be at least 6 millimeters.

A further aspect of this disclosure is directed to a method of producingan aluminum alloy vehicle structural component defining an out-of-planeaperture. A first step in this method includes selecting an aluminumalloy blank having a thickness. A second step in this method includesforming the blank such that a bed sub-portion is formed substantiallyparallel to and out-of-plane from a main portion by a distance of atleast 2.5 times the thickness and defines and surrounds an aperture byat least 6 millimeters.

In this aspect, the step of forming the blank may also include drawingthe bed sub-portion from the main portion and strain hardening a doublecurvature strain hardened sub-portion between the bed sub-portion andthe main portion. The double curvature strain hardened sub-portion mayhave a first radius and a second radius each at least 3 times thethickness. Also in this aspect, the step of forming the blank mayinclude punching the aperture substantially simultaneously with thedrawing of the bed sub-portion.

The above aspects of this disclosure and other aspects will be explainedin greater detail below with reference to the attached drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a pickup truck cab and box on a frame.

FIG. 2 is a partial exploded view of a pickup truck cab.

FIG. 3 is a partial perspective view of an aluminum alloy structuralcomponent defining an out-of-plane aperture.

FIG. 4 is a cross-sectional view taken along line 4-4 in FIG. 3.

FIG. 5 is a partial top view of an aluminum alloy structural componentdefining an out-of-plane slotted aperture.

FIG. 6 is a top view of an aluminum alloy structural component definingan out-of-plane cluster of apertures.

DETAILED DESCRIPTION

The illustrated embodiments are disclosed with reference to thedrawings. However, it is to be understood that the disclosed embodimentsare intended to be merely examples that may be embodied in various andalternative forms. The figures are not necessarily to scale and somefeatures may be exaggerated or minimized to show details of particularcomponents. The specific structural and functional details disclosed arenot to be interpreted as limiting, but as a representative basis forteaching one skilled in the art how to practice the disclosed concepts.

FIG. 1 shows a not-yet-complete pickup truck 10 having a body 12 mountedon a frame 14. The body 12 has a cab 16 and a box 18. The body structure12 may comprise a number of structural automotive components 20. Thestructural components 20 may be aluminum alloys. The structuralcomponents may be 5xxx series and 6xxx series aluminum alloys.

FIG. 2 shows a partial exploded view of the cab 16 illustrating anexample of a number of structural components 20. A roof panel 24, a sidedoor opening structure 26, and a number of reinforcement members 28, 30a, 30 b, 30 c, 32 are labeled. The reinforcement members 30 a, 30 b, 30c may be assembled to provide a roof-header assembly 34. The roof-headerassembly 34 connects a portion of the roof panel 24 to the sidestructure 26 and provides structural support for the cab 16 of thepickup truck 10. Other structural components 20 shown may also beincluded to provide the roof-header assembly 34.

All of the components shown in FIG. 2, whether labeled or not, may beconsidered structural components 20. As well other components not shownin FIG. 2, such as those that make up the box 18 (see FIG. 1), may alsobe considered structural components 20. Structural components 20 includeexterior body panels, interior body panels, reinforcement members, andconnecting members that allow for all of the previous mentionedcomponents to be assembled together. All of the components in FIG. 2,labeled or not labeled, may be made from 6xxx series aluminum alloy. Theroof-header assembly 34 may be a 6111 aluminum alloy.

Vehicle frame 14 and body assemblies 12 (see FIG. 1) may be assembled byjoining individual formed components (i.e. 28, 30 a, 30 b, 30 c, 32).Joining methods may include Resistance Spot Welding (RSW), Self-PiercingRivets (SPR) and the use of other fasteners such as bolts. During theprocess of assembly, access apertures may be required in some of thecomponents to permit manufacturing tools access to join the components.For example, RSW may require access apertures for weld gun access, SPRmay requires access apertures for SPR guns, and for bolts and/or nuts, anut runner tool may require an aperture for accessing a joint andcoupling several parts together. In addition, apertures may also be usedfor E-coat draining and weight reduction.

FIGS. 3 and 4 show perspective and cross-sectional views, respectively,of portion of a structural component 20 defining an aperture 40. Thestructural component 20 has a main portion 42 surrounding a recessedportion 44. The recessed portion 44 has a strain hardened sub-portion 46and a bed sub-portion 48. The strain hardened sub-portion 46 is disposedbetween the main portion 42 and bed sub-portion 48. The strain hardenedsub-portion 46 connects the bed sub-portion 48 to the main portion 42. Aportion of the strain hardened sub-portion 46 may have a hardness higherthan the main portion 42. The recessed portion 44 may extend inwardlyinto the structural component 20, as shown in FIG. 3, or may be invertedto extend outwardly from the structural component 20.

The main portion 42 has a first thickness 50 and a first surface 52. Thefirst surface 52 is substantially flat and may be used to define a firstplane 54. The bed sub-portion 48 has a second thickness 56 and a secondsurface 58. The second surface 58 is substantially flat and may be usedto define a second plane 60. The second thickness 56 may besubstantially equal to the first thickness 50. The structural component20 may have a substantially constant thickness 50, 56 proximate theaperture 40. For example, the thickness 50, 56 may 2 millimeters.Substantially, as used in this patent application, does not meanexactly, thus some tolerance may be given and a person of skill in theart may determine a fair amount of tolerance for each feature that theterm substantially modifies. For example, the second thickness 56 may bethinner than the first thickness 50 due to a drawing of the material toform the recessed portion 44 and still be considered substantially equalto each other.

The second surface 58 may be substantially parallel with the firstsurface 52, and with substantial flatness's and being substantiallyequal thicknesses 50, 56, it may be said that the bed sub-portion 48 issubstantially parallel with the main portion 42. A depth 62 may bedefined between the first surface 52 and the second surface 58. Thedepth 62 may be at least 2.5 times the first thickness 50. For example,if the structural component 20 has a thickness 50 of 2 millimeters, thedepth would be at least 5 millimeters. The depth 62 may also beconstrained to be within 4 times the thickness 50 for manufacturabilityconsiderations. The depth 62 of the first surface 52 of the main portion42 (used to define the first plane 54) from the second surface 58 of thebed sub-portion 48 (used to define the second plane 60) provides thatthe bed sub-portion 48 is out-of-plane with the main portion 42.

The bed sub-portion 48 defines the aperture 40. The aperture 40 may besubstantially circular, however other shapes may be used and multipleapertures may be clustered together. The aperture 40 may have a diameter64 of at least 4 millimeters. The bed sub-portion 48 also defines aperimeter 66 of the aperture 40. The bed sub-portion 48 has a width 68extending substantially perpendicularly from the perimeter 66. The width68 may be at least 6 millimeters such that the bed sub-portion 48extends a minimum of 6 millimeters from every point along the perimeter66 of the aperture 40. The aperture 40 may be an access hole used duringassembly of the component. An access hole may have a diameter 64 of atleast 16 millimeters.

A first interface 72 may be defined that extends between the mainportion 42 and the strain hardened sub-portion 46. The first interface72 may be considered to be part of the strain hardened sub-portion 46and connected to the main portion 42 as opposed to being disposedbetween the two. The first interface 72 has a first radius 74. The firstradius 74 may be at least 3 times the first thickness 50. For example,if the structural component 20 has a thickness 50 of 2 millimeters, thefirst radius 74 would be at least 6 millimeters.

A second interface 76 may be defined extends between the strain hardenedsub-portion 46 and the bed sub-portion 48. The second interface 76 maybe considered to be part of the strain hardened sub-portion 46 andconnected to the bed sub-portion 48 as opposed to being disposed betweenthe two. The second interface 76 has a second radius 78. The secondradius 78 may be at least 3 times the first thickness 50. For example,if the structural component 20 has a thickness 50 of 2 millimeters, thefirst radius 74 would be at least 6 millimeters.

The recessed portion 44 may have an overall footprint 80. The footprint80 surrounding a circular aperture 40 may have a depth-to-footprintratio. The depth-to-footprint ratio may be determined by dividing thefootprint 80 by the depth 62. A depth-to-footprint ratio between 0.05and 0.2 may be desirable. For example, a structural member 20 having arecessed portion 44 defining a circular aperture 40 may have a depth 62of 5 millimeters and a footprint 80 of 33 millimeters. The recessedportion 44 in this example may have a depth-to-footprint ratio of 0.15.

The recessed portion 44 may provide a stiffened ring of material aroundthe aperture 40 at least partially due to the alternating doublecurvature of the first and second interfaces 72, 76 and themanufacturing of the structural component 20 to achieve the geometricshape. Additional strain hardening processes may be conducted to thestrain-hardened sub-portion 46 outside of the manufacturing process usedto define the shape. In addition, the recessed portion 44 defines theaperture 40 out-of-plane from the main portion 42. Thus, if the mainportion 42 is subjected to in-plane tension, such as due to a bending,the strain in the structural component 20 primarily concentrates alongthe strain hardened sub-portion 46 (the stiffened ring) and by-passesthe aperture 40. As a result the perimeter 66 of the aperture 40undergoes less straining than if the aperture 40 was in-plane with themain portion 42.

The aperture 40 being defined out-of-plane from the main portion 42, thebed sub-portion 48 surrounding the aperture 40, and the strain hardenedsub-portion 46 surrounding the bed sub-portion 48 may improve theoverall structural robustness of the aluminum alloy structural component20.

FIG. 5 is a partial top view of an aluminum alloy structural component20 defining an out-of-plane slotted aperture 84. The slotted aperture 84is a representation that an aperture may have any geometric shape. Theslotted aperture has a perimeter 86. As before, a width 88 extendssubstantially perpendicularly from the perimeter 86. The width 88 mayextend a minimum of 6 millimeters from every point along the perimeter86 of the aperture 84.

FIG. 6 is a partial top view of an aluminum alloy structural component20 defining an out-of-plane cluster of apertures 90, 92. A circularfirst aperture 90 and a square second aperture 92 are shown as examplesof clustered apertures having varying geometries. Any number ofapertures may be included in a cluster. Different from the embodimentslisted above is that the perimeter 94 is not just the edge of thegeometric shape, but the overall boundary of all of the clusteredapertures, sharing edge boundaries of one geometric shape and travelingfrom one aperture 90 to another aperture 92, as shown in the figure. Awidth 96, like before, then extends substantially perpendicularly fromthe perimeter 94. The width 96 may extend a minimum of 6 millimetersfrom every point along the perimeter 94 of the apertures 90, 94. Notethat the distance between apertures 90, 92 may be greater or less than 6millimeters.

A method of manufacturing may be conducted to produce the structuralcomponent 20 as described above. The structural component 20, in thiscase, may be an aluminum alloy vehicle structural component defining anout-of-plane aperture. A first step in this method may include selectingan aluminum alloy blank having a known thickness. The blank may be cutfrom a roll of substantially constant thickness aluminum alloy. A secondstep in the method may include forming the blank such that a bedsub-portion is formed substantially parallel to and out-of-plane from amain portion by a distance of at least 2.5 times the thickness anddefines and surrounds an aperture by at least 6 millimeters.

The forming step may include drawing the bed sub-portion from the mainportion. Drawing is a stamping operation. The forming step may alsoinclude strain hardening a double curvature strain hardened sub-portionbetween the bed sub-portion and the main portion. The strain hardeningmay be performed by the drawing operation. The method may also include,or alternatively include, a separate strain hardening operationperformed on the strain hardened sub-portion. The double curvaturestrain hardened sub-portion may have a first radius and a second radiuseach at least 3 times the thickness.

The step of forming the blank may also include punching the aperture.The aperture may be punched at substantially the same time as thedrawing the bed sub-portion. Alternatively, the aperture may be cut outafter the bed sub-portion is formed. As well, the aperture may be formedfirst and the bed-sub portion formed around the aperture.

While exemplary embodiments are described above, it is not intended thatthese embodiments describe all possible forms of the disclosed apparatusand method. Rather, the words used in the specification are words ofdescription rather than limitation, and it is understood that variouschanges may be made without departing from the spirit and scope of thedisclosure as claimed. The features of various implementing embodimentsmay be combined to form further embodiments of the disclosed concepts.

What is claimed is:
 1. A pickup truck comprising: an aluminum alloystructural component having a side including a main portion defining abed sub-portion that is encircled by the main portion and isout-of-plane with the main portion, the bed sub-portion beingsubstantially parallel to the main portion and connected to the mainportion by a strain hardened sub-portion, wherein the bed sub-portiondefines an aperture, and wherein the main portion has a substantiallyflat first surface, the bed sub-portion has a substantially flat secondsurface substantially parallel with the first surface, and a depthbetween the first surface to the second surface is at least 2.5 times athickness of the main portion.
 2. The pickup truck of claim 1 whereinthe bed sub-portion has a thickness that is substantially equal to athickness of the main portion.
 3. A pickup truck comprising: an aluminumalloy structural component having a side including a main portiondefining a bed sub-portion that is encircled by the main portion and isout-of-plane with the main portion, the bed sub-portion beingsubstantially parallel to the main portion and connected to the mainportion by a strain hardened sub-portion, wherein the bed sub-portiondefines an aperture, and wherein a first interface extends between themain portion and the strain hardened sub-portion having a first radiusand a second interface extends between the strain hardened sub-portionand the bed sub-portion having a second radius, and wherein the firstand second radii are at least 3 times a thickness of the main portion.4. The pickup truck of claim 1 wherein the aperture is substantiallycircular.
 5. The pickup truck of claim 4 wherein the aperture has adiameter of at least 16 millimeters.
 6. The pickup truck of claim 1wherein the aperture is an access hole used during assembly of thecomponent.
 7. The pickup truck of claim 1 wherein the aluminum alloystructural component is a 6000 series aluminum alloy.